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Yamaha YZ250F 2009 Owner'S Service Manual Download Page 35

2-13

TIGHTENING TORQUES

△

Brake caliper and bleed screw

M8 × 1.25

2

6

0.6

4.3

△

Front wheel axle and axle nut

M16 × 1.5

1

105

10.5

75

△

Front wheel axle holder

M8 × 1.25

4

21

2.1

15

△

Front brake disc

M6 × 1.0

6

12

1.2

8.7

△

Rear brake disc

M6 × 1.0

6

14

1.4

10

△

Footrest bracket and frame

M10 × 1.25

4

55

5.5

40

△

Brake pedal

M8 × 1.25

1

26

2.6

19

△

Rear brake master cylinder

M6 × 1.0

2

10

1.0

7.2

Rear brake master cylinder cap

M4 × 0.7

2

2

0.2

1.4

△

Rear brake hose union bolt

M10 × 1.25

2

30

3.0

22

△

Rear wheel axle and axle nut

M22 × 1.5

1

135

13.5

98

△

Nipple (spoke)

—

72

3

0.3

2.2

△

Rear wheel sprocket

M8 × 1.25

6

42

4.2

30

△

Rear brake disc cover

M6 × 1.0

2

10

1.0

7.2

△

Rear brake caliper protector

M6 × 1.0

2

7

0.7

5.1

Drive chain puller adjust bolt and locknut

M8 × 1.25

2

19

1.9

12

Engine mounting:

△

Engine and engine bracket (front)

M10 × 1.25

1

53

5.3

38

△

Engine and frame (lower)

M10 × 1.25

1

53

5.3

38

△

Upper engine bracket and frame

M8 × 1.25

4

34

3.4

25

△

Lower engine bracket and frame

M8 × 1.25

4

38

3.8

27

△

Engine and engine bracket (upper)

M10 × 1.25

1

55

5.5

40

Lower engine guard

M6 × 1.0

3

10

1.0

7.2

△

Right engine guard

M6 × 1.0

1

10

1.0

7.2

CDI unit bracket

M6 × 1.0

2

7

0.7

5.1

Cable guide and CDI unit bracket

M5 × 0.8

2

4

0.4

2.9

Cable guide and frame

M5 × 0.8

1

5

0.5

3.6

△

Pivot shaft and nut

M16 × 1.5

1

85

8.5

61

△

Relay arm and swingarm

M14 × 1.5

1

70

7.0

50

△

Relay arm and connecting rod

M14 × 1.5

1

80

8.0

58

△

Connecting rod and frame

M14 × 1.5

1

80

8.0

58

△

Rear shock absorber and frame

M10 × 1.25

1

56

5.6

40

△

Rear shock absorber and relay arm

M10 × 1.25

1

53

5.3

38

△

Rear frame (upper)

M8 × 1.25

1

38

3.8

27

△

Rear frame (lower)

M8 × 1.25

2

32

3.2

23

△

Swingarm and brake hose holder

M5 × 0.8

4

3

0.3

2.2

Swingarm and patch

M4 × 0.7

4

2

0.2

1.4

Upper drive chain tensioner

M8 × 1.25

1

16

1.6

11

Lower drive chain tensioner

M8 × 1.25

1

16

1.6

11

Drive chain support

M6 × 1.0

3

7

0.7

5.1

△

Seal guard and swingarm

M5 × 0.8

4

6

0.6

4.3

△

Fuel tank mounting boss and frame

M10 × 1.25

1

20

2.0

14

△

Fuel tank

M6 × 1.0

2

9

0.9

6.5

△

Fuel cock

M6 × 1.0

2

4

0.4

2.9

Part to be tightened

Thread size

Q'ty

Tightening torque

Nm

m•kg

ft•lb

Summary of Contents for YZ250F 2009

Page 1: ...t ce manuel avant la première utilisation du véhicule Read this manual carefully before operating this vehicle Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen Leggere attentamente questo manuale prima di utilizzare questo veicolo ...

Page 2: ...ule Le manuel doit être remis avec le véhicule en cas de vente de ce dernier Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen Diese Bedienungsanleitung muss wenn das Fahrzeug verkauft wird beim Fahrzeug verbleiben Leggere attentamente questo manuale prima di utilizzare il veicolo Questo manuale dovrebbe accompa gnare il veicolo se viene venduto ...

Page 3: ...YZ250F Y 2009 2009 5XC 28199 35 E0 5XC 28199 35 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating this vehicle ...

Page 4: ......

Page 5: ... S SERVICE MANUAL 2008 by Yamaha Motor Co Ltd 1st Edition May 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...racter istics THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine ALWAYS WEAR PROTECTIVE APPAREL When operating this machine al ways wear an approved helmet with goggles or a face shield Also wear heavy boots gloves and protective clothing Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine...

Page 7: ...wn to find the required fore edge symbol mark and go to a page for required item and de scription MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The information has been complied to provide the me chanic with an easy to read handy reference that contains comprehen sive explanations of all disassembly repair assembly and inspection op erations I...

Page 8: ...informa tion the step by step format sup plements 5 are given in addition to the exploded diagram and job instruction chart ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 7 are used to identify the specifications appear ing in the text 1 With engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening 6 Specified value Service limit 7 Resistance Ω Voltage V Elect...

Page 9: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 ELECTRICAL 6 TUNING 7 ...

Page 10: ... 3 14 ELECTRICAL 3 24 CHAPTER 4 ENGINE SEAT FUEL TANK AND SIDE COVERS 4 1 EXHAUST PIPE AND SILENCER 4 3 RADIATOR 4 5 CARBURETOR 4 7 CAMSHAFTS 4 14 CYLINDER HEAD 4 19 VALVES AND VALVE SPRINGS 4 21 CYLINDER AND PISTON 4 25 CLUTCH 4 29 OIL FILTER ELEMENT AND WATER PUMP 4 33 BALANCER 4 37 OIL PUMP 4 39 KICK SHAFT AND SHIFT SHAFT 4 42 CDI MAGNETO 4 47 ENGINE REMOVAL 4 49 CRANKCASE AND CRANKSHAFT 4 53 T...

Page 11: ...ct to change without notice 1 Clutch lever 2 Hot starter lever 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 Engine stop switch 8 Kickstarter crank 9 Fuel tank 10 Radiator 11 Coolant drain bolt 12 Rear brake pedal 13 Valve joint 14 Fuel cock 15 Cold starter knob 16 Drive chain 17 Air filter 18 Oil level check window 19 Shift pedal 20 Front fork 1 ...

Page 12: ...e joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose In this installation make sure the arrow faces the fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke JET NEEDLE PULL UP TOOL The jet needle pull up tool 1 is used to pull the jet ne...

Page 13: ...amped letters must be on the side exposed to view When in stalling oil seal s apply a light coating of lightweight lithium base grease to the seal lip s Oil the bearings liberally when installing Do not use compressed air to spin the bearings dry This causes dam age to the bearing surfaces CIRCLIPS 1 All circlips should be inspected carefully before reassembly Al ways replace piston pin clips afte...

Page 14: ...ase separating tool YU 1135 A 90890 01135 These tool is used to remove the crankshaft from either case Flywheel puller YM 1189 90890 01189 This tool is used to remove the fly wheel magneto Rotor holding tool YU 1235 90890 01235 This tool is used when loosening or tightening the flywheel magneto se curing nut Dial gauge and stand YU 3097 90890 01252 Stand YU 1256 These tools are used to check each ...

Page 15: ...01500 90890 01500 This tool is used to loosen or tighten the base valve Cap bolt ring wrench YM 01501 90890 01501 This tool is used to loosen or tighten the damper assembly Fork seal driver YM A0948 90890 01502 This tool is used when install the fork oil seal Spoke nipple wrench YM 01521 90890 01521 This tool is used to tighten the spoke Pocket tester YU 3112 C 90890 03112 Use this tool to inspect...

Page 16: ...oss securing nut Valve guide remover Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4111 90890 04111 YM 4116 90890 04116 This tool is needed to remove and install the valve guide Valve guide installer Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4112 90890 04112 YM 4117 90890 04117 This tool is needed to install the valve guide Valve guide reamer Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM...

Page 17: ...necessary for checking the ignition system compo nents Digital tachometer YU 39951 B 90890 06760 This tool is needed for observing en gine rpm YAMAHA Bond No 1215 ThreeB ond No 1215 90890 85505 This sealant Bond is used for crankcase mating surface etc Tool name Part number How to use Illustration ...

Page 18: ...EAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine Press down on the brake pedal to activate the rear brake FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel The fuel cock has the two posi tions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not running ON W...

Page 19: ...he cold starter knob to its original position and run the en gine at 3 000 5 000 r min for 1 or 2 minutes Since this model is equipped with an accelerator pump if the engine is raced the throttle opened and closed the air fuel mixture will be too rich and the engine may stall Also unlike a two stroke engine this model can idle Do not warm up the engine for ex tended periods of time STARTING A WARM...

Page 20: ... 2 open low to me dium speed for about one hour 6 Restart the engine and check the operation of the machine through out its entire operating range Re start the machine and operate it for about 10 to 15 more minutes The machine will now be ready to race After the break in or before each race you must check the entire machine for loose fittings and fasteners as per TORQUE CHECK POINTS Tighten all su...

Page 21: ...ink type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of wheel axle Tightening of axle holder Rear Tightening of wheel axle Wheel to rear wheel sprocket Brake Front Brake caliper to front fork Brake disc to ...

Page 22: ...ain with a paper towel and lubri cate the chain to prevent rust 7 Clean the seat with a vinyl uphol stery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed surfac es Avoid combination cleaner waxes as they may contain abra sives 9 After completing the above start the engine and allow it to idle for several minutes STORAGE If your machine is to b...

Page 23: ...t Without oil and fuel 92 7 kg 204 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 249 cm3 8 76 Imp oz 8 42 US oz Bore stroke 77 0 53 6 mm 3 03 2 11 in Compression ratio 13 5 1 Starting system Kickstarter Lubrication system Dry sump Oil type or grade Engine oil For USA and CDN Yamalube 4 SAE10W 40 or SAE20W 50 Yamalube 4 R SAE10W...

Page 24: ...system Chain drive Secondary reduction ratio 49 13 3 769 51 13 3 923 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 30 14 2 143 2nd 28 16 1 750 3rd 29 20 1 450 4th 27 22 1 227 5th 25 24 1 042 Chassis USA CDN EUROPE AUS NZ ZA Frame type Semi double cra dle Caster angle 27 2 26 9 27 1 Trail 117 8 mm 4 64 in 115 0 mm 4 53 in 117 2 mm 4 61 in Tire Type With tube S...

Page 25: ...02 in Cylinder Bore size 77 00 77 01 mm 3 0315 3 0319 in Out of round limit 0 05 mm 0 002 in Camshaft Drive method Chain drive Left Camshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft outside diameter 21 959 21 972 mm 0 8645 0 8650 in Shaft to cap clearance 0 028 0 062 mm 0 0011 0 0024 in 0 08mm 0 003 in Cam dimensions Intake A 30 246 30 346 mm 1 1908 1 1947 in 30 146 mm 1 1869...

Page 26: ...9 0 0059 in EX 0 17 0 22 mm 0 0067 0 0087 in Valve dimensions A head diameter IN 22 9 23 1 mm 0 9016 0 9094 in A head diameter EX 24 4 24 6 mm 0 9606 0 9685 in B face width IN 2 26 mm 0 089 in B face width EX 2 26 mm 0 089 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in C seat width EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 8 mm 0 0315 in D margin thic...

Page 27: ...04 in Valve seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve seat width EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve spring Free length IN 37 81 mm 1 49 in 36 81mm 1 45 in Free length EX 37 54 mm 1 48 in 36 54mm 1 44 in Set length valve closed IN 29 13 mm 1 15 in Set length valve closed EX 29 30 mm 1 15 in Compressed force installed IN 99 114 N at 29 13 mm 9 9 11 4 kg at 2...

Page 28: ...s B T 0 90 2 75 mm 0 04 0 11 in End gap installed 0 15 0 25 mm 0 006 0 010 in 0 50mm 0 020 in Side clearance installed 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring Type Taper Dimensions B T 0 80 2 75 mm 0 03 0 11 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 80mm 0 031 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimensions B T 1 50 2 25 mm 0 06 0 0...

Page 29: ...4 mm 0 0004 0 0017 in Clutch release method Inner push cam push Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Kick and ratchet type Carburetor USA CDN EUROPE AUS NZ ZA Type manufacturer FCR MX37 KEIHIN I D mark 5XCR R0 5XCS S0 Main jet M J 178 Main air jet M A J ø2 0 Jet needle clip position J N NHKR 4 NFLR 5 Cutaway C A 1 5 Pilot jet P J 42 ...

Page 30: ...tor capacity total 0 58 L 0 51 Imp qt 0 61 US qt Water pump Type Single suction centrifugal pump Item Standard Limit Item Standard Limit Steering system Steering bearing type Taper roller bearing Front suspension USA CDN EUROPE AUS NZ ZA Front fork travel 300 mm 11 8 in Fork spring free length 454 mm 17 9 in 449 mm 17 7 in Spring rate STD K 4 4 N mm 0 449 kg mm 25 1 lb in K 4 5 N mm 0 459 kg mm 25...

Page 31: ...ck 50 60 mm 2 0 2 4 in Chain length 15 links 242 9 mm 9 563 in Front disc brake Disc outside dia Thickness 250 3 0 mm 9 84 0 12 in 250 2 5 mm 9 84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 9 52 mm 0 375 in Caliper cylinder inside dia 22 65 mm 0 892 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness 245 4 0 mm 9 65 0 16 in 245 3 5 mm 9 65 0 1...

Page 32: ... 6 mm 0 24 in Primary coil resistance 0 08 0 10 Ωat 20 C 68 F Secondary coil resistance 4 6 6 8 kΩat 20 C 68 F Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Spark plug M10S 1 0 1 13 1 3 9 4 Camshaft cap M6 1 0 10 10 1 0 7 2 Cylinder head blind plug screw M12 1 0 1 28 2 8 20 Cylinder head stud bolt M6 1 0 2 7 0 7 5 1 Cylinder head stud bolt M8 1 25 1 15 1 5 11 Cylinder head ...

Page 33: ...1 0 1 2 0 2 1 4 Hot starter cable adjust bolt and locknut M6 0 75 1 4 0 4 2 9 Air filter case M6 1 0 2 8 0 8 5 8 Air filter joint and air filter case M5 0 8 1 4 0 4 2 9 Air filter element M6 1 0 1 2 0 2 1 4 Exhaust pipe M8 1 25 2 20 2 0 14 Exhaust pipe protector M6 1 0 3 10 1 0 7 2 Silencer M8 1 25 2 30 3 0 22 Silencer clamp M8 1 25 1 16 1 6 11 Crankcase M6 1 0 11 12 1 2 8 7 Crankcase bearing stop...

Page 34: ... steering ring nut M28 1 0 1 Refer to TIP Front fork and damper assembly M51 1 5 2 30 3 0 22 Front fork and adjuster M22 1 25 2 55 5 5 40 Damper assembly and base valve M42 1 5 2 29 2 9 21 Adjuster and damper assembly M12 1 25 2 29 2 9 21 Front fork bleed screw and base valve M5 0 8 2 1 0 1 0 7 Front fork and front fork protector M6 1 0 6 5 0 5 3 6 Lower bracket and brake hose guide M6 1 0 1 4 0 4...

Page 35: ...ngine bracket and frame M8 1 25 4 38 3 8 27 Engine and engine bracket upper M10 1 25 1 55 5 5 40 Lower engine guard M6 1 0 3 10 1 0 7 2 Right engine guard M6 1 0 1 10 1 0 7 2 CDI unit bracket M6 1 0 2 7 0 7 5 1 Cable guide and CDI unit bracket M5 0 8 2 4 0 4 2 9 Cable guide and frame M5 0 8 1 5 0 5 3 6 Pivot shaft and nut M16 1 5 1 85 8 5 61 Relay arm and swingarm M14 1 5 1 70 7 0 50 Relay arm and...

Page 36: ...1 0 4 7 0 7 5 1 Air scoop and fuel tank M6 1 0 6 7 0 7 5 1 Air scoop and radiator guard lower M6 1 0 2 7 0 7 5 1 Front fender M6 1 0 4 7 0 7 5 1 Rear fender front M6 1 0 2 7 0 7 5 1 Rear fender rear M6 1 0 2 16 1 6 11 Side cover M6 1 0 2 7 0 7 5 1 Seat M8 1 25 2 23 2 3 17 Number plate M6 1 0 1 7 0 7 5 1 Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Part to be tightened Thre...

Page 37: ...ts should be at room temperature A Distance between flats B Outside thread diameter DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFI CATION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unit Read Definition Measure mm millimeter 10 3 meter Length cm centimeter 10 2 meter Length kg kilogram 103 gram Wei...

Page 38: ...2 16 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Intake camshaft 6 Exhaust camshaft 7 Oil tank 8 Oil delivery pipe A To oil tank ...

Page 39: ...2 17 LUBRICATION DIAGRAMS 1 Crankshaft 2 Oil filter element 3 Oil tank 4 Oil hose A From oil pump ...

Page 40: ...uel hose 12 Carburetor overflow hose A Insert the end of the fuel tank breather hose into the hole in the steering stem B Install the connector cover so that it does not come in between the radiator hose 1 and radiator C Aligh the paint mark on the cylin der head breather hose with the front end of the hose guide D Pass the cylinder head breather hose on the outside of the radia tor hose 1 and the...

Page 41: ...s the fuel hose on the out side of throttle position sensor lead H Pass the carburetor breater hos es so that they are not pinched between the upper engine bracket and carburetor I Pass the carburetor breather hoses and overflow hose so that all there hoses do not contact the rear shock absorber ...

Page 42: ...gine stop switch lead 14 Sub wire harness 15 CDI unit bracket 16 CDI unit 17 Throttle cable 18 Cylinder head breather hose 19 Hot starter cable protector 20 Rubber cap A Fasten the hot starter cable throttle cables throttle position sensor lead and ignition coil lead B Fasten the neutral switch lead on the oil hose C Pass the neutral switch lead on the inside of the oil hose D Fasten the neutral s...

Page 43: ...et at the white taped portion of the subwire har ness and with the clamp ends facing downward H Locate the clamp ends in the ar rowed range I Fasten the neutral switch lead and CDI magneto lead over the hump of the frame J Fasten the hot starter cable and throttle cable onto the frame K Fasten the throttle position sen sor lead and the hot starter ca ble L Locate the clamp between the hot starter ...

Page 44: ... Cylinder head breather hose 6 Clamp 7 Rear arm bracket A Pass the throttle cables over the radiator hose 2 B Pass the cylinder head breather hose so that it does not contact the ignition coil C Fasten the throttle cables with the clamp so that the cables are not bent and pass them under the rear arm bracket ...

Page 45: ... directs as shown and lightly touches the projec tion on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe portion directs as shown and lightly touches the projec tion on the brake master cylin der ...

Page 46: ...e hose 8 Hose guide A Fasten the engine stop switch lead to the handlebar B Pass the clutch cable and hot starter cable through the cable guide C Pass the brake hose in front of the number plate D Pass the throttle cables through the cable guide E Pass the clutch cable and hot starter cable through the cable guide on the number plate ...

Page 47: ...ENGINE OIL Replace Inspect OIL FILTER ELEMENT OIL STRAINER Clean VALVES Check the valve clearances The engine must be cold Inspect Check the valve seats and valve stems for wear Replace VALVE SPRINGS Inspect Check the free length and the tilt Replace VALVE LIFTERS Inspect Check for scratches and wear Replace CAMSHAFTS Inspect the camshaft surface Inspect Inspect the decompression system Replace TI...

Page 48: ...nspect and clean CARBURETOR Inspect adjust and clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 50 60 mm 2 0 2 4 in Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Replace coolant Every two years Inspect hoses OUTSIDE NUTS AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FI...

Page 49: ... FRONT FORKS Inspect and adjust Replace oil Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect and adjust Lube After rain ride Molybdenum disulfide grease Replace spring seat Every one year Retighten DRIVE CHAIN GUIDE AND ROLLERS Inspect SWINGARM Inspect lube and retighten Molybdenum disulfide ...

Page 50: ...ket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connection Lubricate Yamaha cable lube or SAE 10W 30 motor oil Inspect and clean throttle ca ble Inspect dirt and wear on the throttle cable on the carburetor side HOT STARTER CLUTCH LEVER Inspect free play Item After break in Every race Every third or 500 km Every fifth or 1 000 km As...

Page 51: ...slack and alignment Check that the drive chain is lubricated properly P 3 17 18 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 20 21 Steering Check that the handlebar can be turned smoothly and have no ex cessive play P 3 21 22 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 18 20 Cables w...

Page 52: ... clean tap water 5 Install Copper washer Coolant drain bolt 6 Fill Radiator Engine To specified level Do not mix more than one type of ethylene glycol antifreeze con taining corrosion inhibitors for aluminum engine Do not use water containing im purities or oil Handling notes of coolant The coolant is harmful so it should be handled with special care When coolant splashes to your eye Thoroughly wa...

Page 53: ...LUTCH CABLE FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Clutch lever free play adjustment steps a Loosen the locknuts 1 b Turn the adjuster 2 until free play a is within the specified lim its c Tighten the locknuts Before adjustment expose the ad juster by moving the boot 3 and cap 4 away Make minute adjustment on the le ver side using the...

Page 54: ...r oper ation of hot starter CLEANING THE AIR FILTER ELEMENT Proper air filter maintenance is the biggest key to preventing premature engine wear and damage Never run the engine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove Seat Fitting bolt 1 Washer 2 Air filter element 3 Air filter guide 4 2 Clea...

Page 55: ...warm up for several minutes 6 Turn off the engine and inspect the oil level once again Wait a few minutes until the oil settles before inspecting the oil level CHANGING THE ENGINE OIL 1 Start the engine and warm it up for several minutes and then turn off the engine and wait for five minute 2 Place the machine on a level place and hold it on upright posi tion by placing the suitable stand under th...

Page 56: ...e the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this number as the factory set number of turns out a Turn in the pilot screw until it is lightly seated b Turn out the pilot screw by the factory set number of turns ADJUSTING THE ENGINE IDLING SPEED...

Page 57: ...lve clearance Out of specification Adjust Checking steps a Turn the crankshaft counterclock wise with a wrench b Align the T D C mark a on the rotor with the align mark b on the crankcase cover when piston is at T D C on compression stroke In order to be sure that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake cam shaft must align with ...

Page 58: ...ad number to use Use the new pad number only as a guide when verifying the valve clear ance adjustment f Install the new pads 3 and the valve lifters 4 Apply the engine oil on the valve lift ers Apply the molybdenum disulfide oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place g Install the cam...

Page 59: ...3 13 ENGINE INTAKE EXHAUST ...

Page 60: ... bleeding procedure when the tiny bubbles in the system have disap peared j Add brake fluid to the level line on the reservoir Check the operation of the brake after bleeding the brake system 3 Install Protector rear brake Reservoir float front brake Diaphragm Brake master cylinder cap ADJUSTING THE FRONT BRAKE 1 Check Brake lever position a 2 Remove Brake lever cover 3 Adjust Brake lever position...

Page 61: ... the brake caliper re cesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Inspect Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake lever operation A softy or spongy feeling Bleed brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec tion CHECKING AND REPLACING THE REAR...

Page 62: ...tion A softy or spongy feeling Bleed brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec tion CHECKING THE REAR BRAKE PAD INSULATOR 1 Remove Brake pad Refer to CHECKING AND RE PLACING THE REAR BRAKE PADS section 2 Inspect Rear brake pad insulator 1 Damage Replace CHECKING THE BRAKE FLUID LEVEL 1 Place the brake master cylinder so that its top is in a horizontal po sition 2 Inspect Brake...

Page 63: ... the en gine 2 Check Drive chain slack a Above the seal guard installation bolt Out of specification Adjust Before checking and or adjusting ro tate the rear wheel through several revolutions and check the slack sev eral times to find the tightest point Check and or adjust the drive chain slack with the rear wheel in this tight chain position 3 Adjust Drive chain slack Drive chain slack adjustment...

Page 64: ...HE FRONT FORK REBOUND DAMPING FORCE 1 Adjust Rebound damping force By turning the adjuster 1 STANDARD POSITION This is the position which is back by the specific number of clicks from the fully turned in position Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Always adjust each front fork to the same setting Uneven adjust ment can cause poor ...

Page 65: ... mud from around the locknut and adjust er before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster Never attempt to turn the adjuster beyond the maximum or minimum setting e Tighten the locknut 5 Install Rear frame upper Rear frame lower ADJUSTING THE REAR SHOCK ABSORBER REBOUND DAMPING FORCE 1 Adjust Rebound damping force By turning the adjuster 1 Stan...

Page 66: ...ter with the punch mark b on the adjuster body Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged CHECKING THE TIRE PRESSURE 1 Measure Tire pressure Out of specification Adjust Check the tire while it is cold Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low A tilted tire valve stem indicates tha...

Page 67: ...th action Adjust steer ing ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps a Remove the number plate b Remove the handlebar and upper bracket c Loosen the steering ring nut 1 using the steering nut wrench 2 d Tighten the steering ring nut 3 using steering nut wrench 4 Apply the lithium soap base grease on the thread of the steering stem Set the torque wrench to the steer ing...

Page 68: ...holder is positioned at the mark on the handlebar as shown Insert the end of the fuel breather hose 12 into the hole in the steer ing stem First tighten the bolts on the front side of the handlebar upper holder and then tighten the bolts on the rear side Steering stem nut 145 Nm 14 5 m kg 105 ft lb Handlebar upper holder 28 Nm 2 8 m kg 20 ft lb Pinch bolt upper brack et 21 Nm 2 1 m kg 15 ft lb Num...

Page 69: ...vot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding por tion 8 Throttle cable end 9 Clutch cable end 10 Hot starter cable end A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W 30 motor oil or suitable chain lubricants C Lubricate the following areas with high quality lightweight lith ium soap base grease Wipe off any excess grease and avoid getting grease ...

Page 70: ...er if necessary 5 Tighten Spark plug Before installing a spark plug clean the gasket surface and plug sur face Finger tighten a the spark plug before torquing to specification b CHECKING THE IGNITION TIMING 1 Remove Timing mark accessing screw 1 2 Attach Timing light Digital tachometer To the ignition coil lead orange lead 1 3 Adjust Engine idling speed Refer to ADJUSTING THE EN GINE IDLING SPEED ...

Page 71: ...inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage SEAT FUEL TANK AND SIDE COVERS REMOVING THE SEAT FUEL TANK AND SIDE COVERS Order Part name Q ty Remarks Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Bolt fuel tank 2 4 Fuel tank 1 5 Left side cover 1 Refer to removal s...

Page 72: ...n a is inserted into the band of the number plate Pull the band off the projection before removal Remove the hot starter cable 2 and clutch cable 3 from the cable guide b on the number plate The projection c on the lower bracket is inserted into the number plate Remove the number plate by pulling it off the projection INSTALLING THE AIR SCOOP 1 Install Air scoop 1 Bolt air scoop Put the portion a ...

Page 73: ...rt name Q ty Remarks A Except for USA and CDN Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Collar 1 5 Silencer 1 6 Silencer clamp 1 7 Nut exhaust pipe 2 8 Exhaust pipe 1 9 Gasket 2 10 Wave washer 3 ...

Page 74: ...ke care not to allow the fiber out of place when installing the inner pipe INSTALLING THE SILENCER AND EXHAUST PIPE 1 Install Gasket Exhaust pipe 1 Nut exhaust pipe 2 First temporarily install both nuts then tighten either of these nuts to 13 Nm 1 3 m kg 9 4 ft lb and the other to 20 Nm 2 0 m kg 14 ft lb and then come back to the first one and retighten it to 20 Nm 2 0 m kg 14 ft lb 2 Install Sile...

Page 75: ...ANT sec tion in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Radiator guard 2 2 Radiator hose clamp 8 Only loosening 3 Radiator hose 1 1 4 Left radiator 1 5 Radiator hose 3 1 6 Right radiator 1 7 Radiator hose 2 1 8 Radiator hose 4 1 9 Radiator breather hose 1 10 Radiator pipe 1 1 ...

Page 76: ...in Repair replace INSTALLING THE RADIATOR 1 Install O ring 1 Radiator pipe 1 2 Bolt radiator pipe 3 Apply the lithium soap base grease on the O ring 2 Install Radiator breather hose 1 Radiator hose 2 2 Radiator hose 3 3 Radiator hose 4 4 To right radiator 5 3 Install Right radiator 1 Bolt right radiator 2 Radiator hose 3 3 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 4 Install Left rad...

Page 77: ...tle position sensor lead coupler 1 3 Throttle cable cover 1 4 Throttle cable 2 5 Clamp air filter joint 1 Loosen the screw air filter joint 6 Clamp carburetor joint 1 Loosen the screws carburetor joint 7 Hot starter plunger 1 8 Carburetor assembly 1 9 Carburetor joint 1 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 2 Nm 0 2 m kg 1 4 ft lb 3 Nm 0 3 m kg 2 2 ft lb 3 Nm 0 3 m kg 2 2 ft lb 11 Nm 1 1...

Page 78: ...using cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 10 Float chamber 1 11 Leak jet 1 12 Pilot screw 1 Refer to removal section 13 Float pin 1 14 Float 1 15 Needle valve 1 16 Main jet 1 17 Needle jet 1 18 Spacer 1 ...

Page 79: ...BURETOR 19 Pilot jet 1 20 Starter jet 1 21 Push rod 1 Pull the push rod 22 Throttle shaft assembly 1 23 Push rod link lever assembly 1 24 Pilot air jet 1 25 Cold starter plunger 1 Order Part name Q ty Remarks ...

Page 80: ...Clogged Clean CHECKING THE THROTTLE VALVE 1 Check Free movement Stick Repair or replace Insert the throttle valve 1 into the carburetor body and check for free movement CHECKING THE JET NEEDLE 1 Inspect Jet needle 1 Bends wear Replace Clip groove Free play exists wear Replace Clip position MEASURING AND ADJUSTING THE FLOAT HEIGHT 1 Measure Float height a Out of specification Adjust Measurement and...

Page 81: ...1 fits on the stopper a of the lever 2 4 Install Spring 2 1 To lever 2 2 5 Install Push rod link lever assembly 1 Make sure the stopper a of the spring 2 fits into the recess b in the carburetor 6 Install Washer 1 Circlip 2 7 Install Spring 1 To throttle shaft 2 Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley 8 Install Throttle shaft assembly 1 Washer met...

Page 82: ... of turns recorded before removing 13 Install O ring Leak jet 1 Float chamber 2 Bolt float chamber 3 Cable holder throttle stop screw cable 4 Hose holder carburetor breather hose 5 14 Install Diaphragm accelerator pump 1 Spring 2 O ring 3 Accelerator pump cover 4 Hose holder drain hose 5 Screw accelerator pump cover 6 Install the diaphragm accelerator pump with its mark a facing the spring 15 Inst...

Page 83: ...joint 1 2 Install Carburetor 1 Install the projection a between the carburetor joint slots 3 Install Hot starter plunger 1 4 Tighten Bolt carburetor joint 1 Bolt air filter joint 2 5 Install Throttle cable pull 1 Throttle cable return 2 6 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY section in the CHAPTER 3 7 Install Throttle cable cover 1 Bolt throttle cable cove...

Page 84: ... Order Part name Q ty Remarks Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 ...

Page 85: ...shaft end accessing screw 1 Refer to removal section 3 Timing chain tensioner cap bolt 1 Refer to removal section 4 Timing chain tensioner 1 Refer to removal section 5 Camshaft cap 2 Refer to removal section 6 Clip 2 Refer to removal section 7 Exhaust camshaft 1 Refer to removal section 8 Intake camshaft 1 Refer to removal section ...

Page 86: ...cap 2 Clip Remove the bolts camshaft cap in a crisscross pattern working from the outside in The bolts camshaft cap must be removed evenly to prevent dam age to the cylinder head cam shafts or camshaft caps 5 Remove Exhaust camshaft 1 Intake camshaft 2 Attach a wire 3 to the timing chain to prevent it from falling into the crank case CHECKING THE CAMSHAFT 1 Inspect Cam lobe Pitting scratches blue ...

Page 87: ...e decompression mechanism cam lever pin 2 projects from the camshaft CHECKING THE TIMING CHAIN TENSIONER 1 Check While pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind the ten sioner rod up fully clockwise When releasing the screwdriver by pressing lightly with fingers make sure that the tensioner rod will come out smoothly If not replace the tensioner as sembly IN...

Page 88: ...use a thin screwdriver and wind the tension er rod up fully clockwise b With the rod fully wound and the chain tensioner UP mark a fac ing upward install the gasket 1 and the timing chain tensioner 2 and tighten the bolt 3 to the specified torque c Release the screwdriver check the tensioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the specified torque 3 Turn Crankshaft Count...

Page 89: ...ncer Refer to EXHAUST PIPE AND SILENCER section Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHAFTS section Upper engine bracket Refer to ENGINE REMOVAL section 1 Radiator pipe 1 2 Oil delivery pipe 1 3 Nut 2 4 Bolt L 135 mm 5 31 in 2 5 Bolt L 145 mm 5 71 in 2 6 Cylinder head 1 7 Timing chain guard exhaust side 1 ...

Page 90: ...d several times INSTALLING THE CYLINDER HEAD 1 Install Dowel pin 1 Cylinder head gasket 2 Timing chain guide exhaust side 3 Cylinder head 4 While pulling up the timing chain in stall the timing chain guide exhaust side and cylinder head 2 Install Washer 1 Cable guide 2 Bolts L 145 mm 5 71 in 3 Bolts L 135 mm 5 31 in 4 Nuts 5 Apply the molybdenum disulfide grease on the thread and contact surface o...

Page 91: ...me Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Refer to removal section 2 Adjusting pad 5 Refer to removal section 3 Valve cotter 10 Refer to removal section 4 Valve spring retainer 5 5 Valve spring 5 6 Valve stem seal 5 7 Valve spring seat 5 8 Exhaust valve 2 9 Intake valve 3 ...

Page 92: ...r to 100 C 212 F a Remove the valve guide using a valve guide remover 1 b Install the new valve guide using a valve guide remover 1 and valve guide installer 2 c After installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance After replacing the valve guide reface the valve seat 3 Inspect Valve face Pitting wear Grind the face Valve stem ...

Page 93: ...ompound enter the gap between the valve stem and the guide b Apply molybdenum disulfide oil to the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly pol ished then clean off all of the compound For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping comp...

Page 94: ...rger pitch d facing upward e Smaller pitch 3 Install Valve cotter While compressing the valve spring with a valve spring compressor 1 in stall the valve cotters 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood Hitting the valve tip with excessive force could damage the valve 5 Install Adjusting pad 1 Valve lifter 2 Apply the molybdenum disulfide oil ...

Page 95: ...STON Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin clip 2 Refer to removal section 4 Piston pin 1 Refer to removal section 5 Piston 1 Refer to removal section 6 Piston ring set 1 Refer to removal section ...

Page 96: ...he piston bottom edge d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with following formula f If out of specification replace the cylinder and replace the piston and piston rings as set CHECKING THE PISTON RING 1 Measure Ring side clearance Use a feeler gauge 1 Out of specification Replace the piston and rings as a set Clean carb...

Page 97: ...ing Offset the piston ring end gaps as shown a Top ring end b 2nd ring end c Oil ring end upper d Oil ring e Oil ring end lower 3 Install Piston 1 Piston pin 2 Piston pin clip 3 Apply engine oil onto the piston pin and piston Be sure that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the...

Page 98: ...the cylinder with one hand while compressing the piston rings with the other hand Pass the timing chain 3 through the timing chain cavity Be careful not to damage the tim ing chain guide 4 during instal lation 4 Install Bolt cylinder 5 Bolt cylinder 10 Nm 1 0 m kg 7 2 ft lb ...

Page 99: ...TER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Clutch spring 5 3 Pressure plate 1 4 Push rod 1 1 5 Circlip 1 6 Washer 1 7 Bearing 1 8 Ball 1 9 Push rod 2 1 10 Friction plate 9 11 Clutch plate 8 12 Nut clutch boss 1 Refer to removal section 13 Lock washer 1 Refer to removal section ...

Page 100: ...4 30 CLUTCH 14 Clutch boss 1 Refer to removal section 15 Thrust washer 1 16 Primary driven gear 1 17 Spacer 1 18 Washer 1 19 Push lever shaft 1 Order Part name Q ty Remarks ...

Page 101: ... 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thick ness gauge 2 CHECKING THE PUSH LEVER SHAFT 1 Inspect Push lever shaft 1 Wear damage Replace CHECKING THE PUSH ROD 1 Inspect Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Wear damage bend Replace INSTALLING THE PUSH LEVER SHAFT 1 Install Push lever shaft 1 Bolt push lever shaft 2...

Page 102: ...iction plates and clutch plates 5 Install Bearing 1 Washer 2 Circlip 3 To push rod 1 4 Apply the engine oil on the bearing and washer 6 Install Push rod 2 1 Ball 2 Push rod 1 3 Apply the engine oil on the push rod 1 2 and ball 7 Install Pressure plate 1 8 Install Clutch spring 1 Bolt clutch spring 2 Tighten the bolts in stage using a crisscross pattern 9 Install Dowel pin 1 Gasket clutch cover 2 1...

Page 103: ... the coolant Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Radiator hose 3 Disconnect at water pump side Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake pedal Refer to ENGINE REMOVAL section Right engine guard 1 Oil filter element cover 1 2 Oil filter element 1 3 Water pump housing 1 4 Oil delivery pipe 1 5 Bolt oil hose 1 6 Kickstarter crank 1 7 Right crankcase cover 1 8 I...

Page 104: ...TER ELEMENT AND WATER PUMP 9 Washer 1 Refer to removal section 10 Impeller shaft 1 Refer to removal section 11 Oil seal 2 Refer to removal section 12 Bearing 1 Refer to removal section Order Part name Q ty Remarks ...

Page 105: ... damage Replace CHECKING THE BEARING 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace CHECKING THE OIL SEAL 1 Inspect Oil seal 1 Wear damage Replace INSTALLING THE OIL SEAL 1 Install Oil seal 1 Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufac ture s marks or numbers facing the right crankcase cover 2 2 Install Bearing 1 Instal...

Page 106: ...ct the crankcase cover when it is pulled 2 Install Oil hose 1 Bolt oil hose 2 3 Install Copper washer 1 Oil delivery pipe 2 Union bolt M8 3 Union bolt M10 4 INSTALLING THE WATER PUMP HOUSING 1 Install Dowel pin 1 O ring 2 Apply the lithium soap base grease on the O ring 2 Install Water pump housing 1 Bolt water pump housing 2 INSTALLING THE OIL FILTER ELEMENT 1 Install Oil filter element 1 O ring ...

Page 107: ...OIL FILTER ELEMENT AND WA TER PUMP section Stator Refer to CDI MAGNETO section 1 Nut primary drive gear 1 Refer to removal section 2 Nut balancer shaft driven gear 1 Refer to removal section 3 Lock washer 1 4 Primary drive gear 1 5 Balancer shaft drive gear 1 6 Lock washer 1 7 Balancer shaft driven gear 1 8 Balancer shaft 1 Refer to removal section ...

Page 108: ...n the center a of the balancer shaft weight along the line connect ing the centers of the crankshaft and balancer shaft 2 Install Balancer shaft driven gear 1 Install the balancer shaft driven gear onto the balancer shaft while aligning the punch mark a on the balancer shaft driven gear with the lower spline b on the balancer shaft end 3 Install Balancer shaft drive gear 1 Align the punched mark a...

Page 109: ...rankcase cover Refer to OIL FILTER ELEMENT AND WA TER PUMP section 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Outer rotor 2 1 6 Circlip 1 7 Inner rotor 2 1 8 Dowel pin 1 9 Oil pump cover 1 10 Outer rotor 1 1 11 Inner rotor 1 1 12 Dowel pin 1 13 Washer 1 14 Oil pump drive shaft 1 15 Rotor housing 1 ...

Page 110: ...G THE OIL TANK Order Part name Q ty Remarks Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 1 Oil hose 2 1 2 Oil hose 1 1 3 Dowel pin 2 4 Oil tank breather hose 1 5 Oil tank 1 6 Oil strainer 1 ...

Page 111: ...otor 1 1 Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover 2 Dowel pin 3 Inner rotor 2 4 Circlip 5 Apply the engine oil on the inner ro tor 2 Fit the dowel pin into the groove in the inner rotor 2 4 Install Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt oil pump assembly L 25 mm 0 94 in 4 Bolt oil pump assembly L 30 mm 1 18 in 5 Apply the engine oil on...

Page 112: ...section 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Shift pedal 1 10 Shift shaft 1 11 Collar 1 12 Torsion spring 1 13 Roller 1 14 Shift guide 1 Refer to removal section 15 Shift lever assembly 1 Refer to removal section 16 Shift lever 1 ...

Page 113: ...4 43 KICK SHAFT AND SHIFT SHAFT 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section Order Part name Q ty Remarks ...

Page 114: ...CKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Inspect Kick gear 1 Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace CHECKING THE SHIFT SHAFT 1 Inspect Shift shaft 1 Bend damage Replace Spring 2 Broken Replace CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Inspect Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace CHECKING THE ST...

Page 115: ...MBLY 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 To kick shaft 8 Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel Align the punch mark a on the ratchet wheel with the punch mark b on the kick shaft 2 Install Torsion spring 1 To kick shaft 2 Make sure the stopper a of the tor sion spring fits into the hole b o...

Page 116: ...on spring clockwise and hook into the proper hole a in the crankcase INSTALLING THE KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 Apply the engine oil on the kick idle gear inner circumference Install the kick idle gear with its de pressed side a toward you ...

Page 117: ...s Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Disconnect the CDI magneto lead Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT section 1 Left crankcase cover 1 2 Nut rotor 1 Refer to removal section 3 Rotor 1 Refer to removal section 4 Stator 1 5 Woodruff key 1 ...

Page 118: ...d portions of the crankshaft and rotor When installing the woodruff key make sure that its flat surface a is in parallel with the crankshaft center line b When installing the rotor align the keyway c of the rotor with the woodruff key 3 Install Washer 1 Nut rotor 2 Use the rotor holding tool 3 4 Connect CDI magneto lead Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 5 Install Dowel pin G...

Page 119: ...ection Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconnect at the engine side Radiator Refer to RADIATOR section Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT section Cylinder head breather hose Refer to CAMSHAFTS section Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 Oil hose and oil tank breather hose Refer to OIL PUMP se...

Page 120: ...oval section 5 Lock washer 1 Refer to removal section 6 Drive sprocket 1 Refer to removal section 7 Clip 1 8 Bolt brake pedal 1 9 Brake pedal 1 10 Upper engine bracket 2 11 Lower engine bracket 2 12 Engine mounting bolt 3 13 Pivot shaft 1 Refer to removal section 14 Engine 1 Refer to removal section Order Part name Q ty Remarks ...

Page 121: ...et 4 Bolt lower engine bracket 5 Patch 6 Engine mounting bolt front 7 Upper engine bracket 8 Bolt upper engine bracket 9 Engine mounting bolt upper 10 Lower engine guard 11 Bolt lower engine guard 12 Apply the molybdenum disulfide grease on the pivot shaft Install the patch with the claw a facing outside the chassis INSTALLING THE BRAKE PEDAL 1 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pe...

Page 122: ...e chain sprocket cov er 3 INSTALLING THE NEUTRAL SWITCH 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 Apply the lithium soap base grease on the O ring 2 Install Hose guide cylinder head breath er hose 1 Bolt hose guide 2 Nut drive sprocket 75 Nm 7 5 m kg 54 ft lb Screw drive chain sprocket cover 8 Nm 0 8 m kg 5 8 ft lb Screw neutral switch 4 Nm 0 4 m kg 2 9 ft lb Bolt h...

Page 123: ... KICK SHAFT AND SHIFT SHAFT section Stator Refer to CDI MAGNETO section Balancer shaft Refer to BALANCER section 1 Timing chain guide intake side 1 2 Timing chain 1 3 Oil delivery pipe 2 1 4 Bolt L 45 mm 1 77 in 6 Refer to removal section 5 Bolt L 55 mm 2 17 in 1 Refer to removal section 6 Bolt L 70 mm 2 76 in 4 Refer to removal section 7 Hose guide 1 Refer to removal section 8 Clutch cable holder...

Page 124: ...4 54 CRANKCASE AND CRANKSHAFT 10 Left crankcase 1 Refer to removal section 11 Oil strainer 1 12 Crankshaft 1 Refer to removal section Order Part name Q ty Remarks ...

Page 125: ...CRANKCASE BEARING Order Part name Q ty Remarks Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Oil seal 2 2 Bearing 10 Refer to removal section ...

Page 126: ... Do not use a hammer to drive out the crankshaft REMOVING THE CRANKCASE BEARING 1 Remove Bearing 1 Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Inspect Timing chain guide Wear damage Replace CHECKING THE CR...

Page 127: ... center with one hand while turning the nut of the installing tool with the other Operate the installing tool un til the crankshaft bottoms against the bearing Before installing the crankshaft clean the contacting surface of crankcase Do not use a hammer to drive in the crankshaft A For USA and CDN B Except for USA and CDN 2 Check Shifter operation Transmission operation Unsmooth operation Repair ...

Page 128: ...crankcase tightening bolts in stage using a crisscross pat tern 7 Install Oil delivery pipe 2 1 O ring 2 Bolt oil delivery pipe 2 3 Apply the lithium soap base grease on the Orings 8 Install Timing chain 1 Timing chain guide intake side 2 Bolt timing chain guide 3 9 Remove Sealant Forced out on the cylinder mating surface 10 Apply Engine oil To the crank pin bearing and oil delivery hole 11 Check ...

Page 129: ...s Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 Refer to removal section 2 Drive axle 1 Refer to removal section 3 Shift cam 1 Refer to removal section 4 Shift fork 3 1 Refer to removal section 5 Shift fork 2 1 Refer to removal section 6 Shift fork 1 1 Refer to removal section 7 Collar 1 ...

Page 130: ...G THE SHIFT FORK SHIFT CAM AND SEGMENT 1 Inspect Shift fork 1 Wear damage scratches Re place 2 Inspect Shift cam 1 Segment 2 Wear damage Replace 3 Check Shift fork movement Unsmooth operation Replace shift fork For a malfunctioning shift fork re place not only the shift fork itself but the two gears each adjacent to the shift fork INSTALLING THE TRANSMISSION 1 Install 5th pinion gear 24T 1 3rd pin...

Page 131: ...tion to the crankcase oil seal lip 5 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 To main axle and drive axle Apply the molybdenum disulfide oil on the shift fork grooves Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main ax le 6 Install Transmission assembly ...

Page 132: ...dertake inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q ty Remarks Hold the machine by placing the suitable stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Fron...

Page 133: ...chine by placing the suitable stand under the engine Refer to HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 3 Refer to removal section 10 Brake disc 1 5 ...

Page 134: ...rake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condi tion replace the brake disc 2 Measure Brake disc thickness a Out of limit Replace INSTALLING THE FRONT WHEEL 1 Install Bearing left 1 Spacer 2 Bearing right 3 Oil seal 4 Apply the lithium soap base grease on the bearing and oil seal lip when installing Use a soc...

Page 135: ...eal 5 Apply the lithium soap base grease on the bearing and oil seal lip when installing Install the bearing with seal facing outward Use a socket that matches the out side diameter of the race of the bearing Right side of bearing shall be in stalled first Install the oil seal with its manufac ture s marks or numbers facing out ward Do not strike the inner race of the bearing Contact should be mad...

Page 136: ...el axle 2 Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 8 Install Right drive chain puller 1 Washer 2 Nut wheel axle 3 Temporarily tighten the nut wheel axle at this point 9 Adjust Drive chain slack a Refer to ADJUSTING THE DRIVE CHAIN SLACK section in the CHAPTER 3 10 Tighten Nut wheel axle 1 Locknut 2 Drive chain...

Page 137: ...tand under the engine Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Union bolt 2 3 Brake hose 1 4 Pad pin plug 1 Remove when loosening the pad pin 5 Pad pin 1 Loosen when disassembling the brake cali per 6 Brake caliper 1 7 Brake lever 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 ...

Page 138: ...ne Refer to HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the brake cali per 8 Brake caliper 1 ...

Page 139: ...rder Part name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal section 6 Brake caliper piston seal 2 1 Refer to removal section ...

Page 140: ...LINDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Push rod Front 1 5 Brake master cylinder boot 1 6 Circlip 1 Use a long nose circlip pliers 7 Washer 1 8 Push rod Rear 1 9 Brake master cylinder kit 1 ...

Page 141: ...l steps a Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the piston out of the brake caliper cylinder with compressed air A Front B Rear REMOVING THE BRAKE CALIPER PISTON SEAL KIT 1 Remove Brake caliper piston dust seal 1 Brake caliper piston seal 2 Remove the brake caliper piston seals and brake caliper piston dust seals by pushing them with a finger Neve...

Page 142: ...on Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper piston dust seal 2 Always use new brake caliper pis ton seals and brake caliper piston dust seals Apply the brake fluid on the brake caliper piston seal Apply the silicone grease on the brake caliper piston dust seal Fit the brake caliper piston seals and brake caliper piston dust seals onto the slot on brake calipe...

Page 143: ...ng installation cause improper brake performance 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller dia side 4 Install Brake master cylinder kit 1 Washer front brake 2 Push rod rear brake 2 Circlip 3 Brake master cylinder boot 4 Push rod front brake 5 To brake master cylinder Apply the brake fluid on the brake master cylinder kit Apply the silicone grease on the...

Page 144: ... Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to ADJUSTING THE REAR BRAKE section in the CHAP TER 3 INSTALLING THE FRONT BRAKE HOSE 1 Install Copper washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the brake caliper 2 Install Brake ho...

Page 145: ...wise the rubber seals may deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the flu id and may result in vapor lock Brake fluid may erode painted...

Page 146: ...or pushing down on the brake pedal check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper A Front B Rear 5 Install rear brake only Protector 1 Bolt protector 2 Bolt protector 7 Nm 0 7 m kg 5 1 ft lb ...

Page 147: ...r to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 1 Protector 1 2 Pinch bolt upper bracket 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Refer to removal section 4 Pinch bolt lower bracket 2 Only loosening 5 Front fork 1 ...

Page 148: ...ring 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 10 Oil seal 1 11 Base valve 1 Drain the fork oil Refer to removal section 12 Damper assembly 1 Drain the fork oil Refer to removal section 30 Nm 3 0 m kg 22 ft lb 29 Nm 2 9 m kg 21 ft lb 29 Nm 2 9 m kg 21 ft lb 1 Nm 0 1 m kg 0 7 ft lb 55 Nm 5 5 m kg 40 ft lb ...

Page 149: ...n the inner tube and locknut 3 Hold the locknut and remove the adjuster Do not remove the locknut as the damper rod may go into the damp er assembly and not be taken out REMOVING THE INNER TUBE 1 Remove Dust seal 1 Stopper ring 2 Using slotted head screwdriver Take care not to scratch the inner tube 2 Remove Inner tube 1 Oil seal removal steps a Push in slowly a the inner tube just before it botto...

Page 150: ...r damage Re place CHECKING THE ADJUSTER 1 Inspect Adjuster 1 O ring 2 Wear damage Replace ASSEMBLING THE FRONT FORK 1 Wash the all parts in a clean sol vent 2 Stretch the damper assembly ful ly 3 Fill Front fork oil 1 To damper assembly Be sure to use recommended fork oil If other oils are used they may have an excessively ad verse effect on the front fork per formance Never allow foreign material...

Page 151: ...y up and down more than 10 times to distribute the fork oil 12 While protecting the damper as sembly 1 with a rag and com pressing fully allow excessive oil to overflow on the base valve side Take care not to damage the damp er assembly 13 Allow the overflowing oil to es cape at the hole a in the damper assembly 14 Check Damper assembly smooth move ment Tightness binding rough spots Repeat the ste...

Page 152: ... dia end a facing the fork spring 25 Install Damper assembly 1 To inner tube 2 To install the damper assembly into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper assembly may fall into it damaging the valve inside 26 Loosen Rebound damping adjuster 1 Loosen the rebound damping ad juster finger tight Record the set position of the ad juster the amount of t...

Page 153: ...on the front fork per formance Never allow foreign materials to enter the front fork 32 Install Damper assembly 1 To outer tube Temporarily tighten the damper as sembly 33 Install Protector guide 1 INSTALLING THE FRONT FORK 1 Install Front fork 1 Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts up per bracket yet 2 Tighten Damper assembly 1 Use the cap bolt ring wre...

Page 154: ...1 Bolt protector 2 6 Adjust Rebound damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position 7 Adjust Compression damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position Pinch bolt upper brack et 21 Nm 2 1 m kg 15 ft lb Pinch bolt lower brack et 21 Nm 2 1 m kg 15 ft lb Bolt protector 5 Nm 0 5 m...

Page 155: ...ver side 4 Clutch lever holder 1 5 Engine stop switch 1 6 Brake master cylinder 1 Refer to removal section 7 Throttle cable cap 1 8 Throttle cable 1 pulled 1 Disconnect at the throttle side 9 Throttle cable 2 pushed 1 Disconnect at the throttle side 10 Right grip 1 Refer to removal section 11 Tube guide 1 12 Collar 1 13 Left grip 1 Refer to removal section 14 Handlebar upper holder 2 15 Handlebar ...

Page 156: ...bar low er holder Change in the direction back to front and installing position of the handlebar lower holder allows the front to rear offset amount of the handlebar position to be changed Do not tighten the nut yet A Forward 2 Install Handlebar 1 Handlebar upper holder 2 Bolt handlebar upper holder 3 The handlebar upper holder should be installed with the punched mark a forward Install the handle...

Page 157: ...etighten the bolts for adjustment 9 Install Grip cap cover 1 Cover throttle cable cap 2 10 Install Brake master cylinder 1 Brake master cylinder bracket 2 Bolt brake master cylinder brack et 3 Install the bracket so that the arrow mark a faces upward First tighten the bolt on the upper side of the brake master cylinder bracket and then tighten the bolt on the lower side 11 Install Engine stop swit...

Page 158: ...um soap base grease on the clutch cable end and hot start er cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY section in the CHAPTER 3 Hot starter lever free play Refer to ADJUSTING THE HOT STARTER LEVER FREE PLAY section in the CHAPTER 3 ...

Page 159: ...der the engine Refer to HANDLING NOTE Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Handlebar Refer to HANDLEBAR section Front fender 1 Steering stem nut 1 2 Front fork 2 Refer to FRONT FORK section 3 Upper bracket 1 4 Steering ring nut 1 Refer to removal section 5 Lower bracket 1 6 Bearing race cover 1 7 Upper bearing 1 8 Lower bearing 1 Refer to removal section 9 ...

Page 160: ...ring races Spin the bearings by hand If the bearings hang up or are not smooth in their operation in the bearing races replace bearings and bearing races as a set INSTALLING THE LOWER BRACKET 1 Install Lower bearing 1 Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install Bearing race Upper bearing 1 Bearing race cover 2 Apply the lithium soap base grease...

Page 161: ... If not adjust the steering by loosen ing the steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to speci fied torque If torqued too much it may cause the front fork to mal function Steering stem nut 145 Nm 14 5 m kg 105 ft lb Front fork top end stan dard a 5 mm 0 20 in Pinch bolt upper brack...

Page 162: ...ING NOTE Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive chain support 1 2 Lower chain tensioner 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 ...

Page 163: ...2 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting rod 1 3 Collar 2 4 Oil seal 2 5 Thrust bearing 2 6 Bushing 2 7 Oil seal 8 8 Bearing 10 Refer to removal section ...

Page 164: ...stall the bearing by pressing it on the side having the manufacture s marks or numbers First install the outer and then the inner bearings to a specified depth from inside 2 Install Bearing 1 Washer 2 Oil seal 3 To relay arm Apply the molybdenum disulfide grease on the bearing when install ing Install the bearing by pressing it on the side having the manufacture s marks or numbers Apply the molybd...

Page 165: ...bdenum disulfide grease on the pivot shaft Insert the pivot shaft from right side 7 Check Swingarm side play a Free play exists Replace thrust bearing Swingarm up and down move ment b Unsmooth movement binding rough spots Grease or replace bearings bushings and collars 8 Install Bolt connecting rod 1 Washer 2 Nut connecting rod 3 Apply the molybdenum disulfide grease on the bolt Do not tighten the...

Page 166: ...nstall Drive chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut lower chain tension er 16 Nm 1 6 m kg 11 ft lb Nut drive chain sup port 7 Nm 0 7 m kg 5 1 ft lb Bolt drive chain support cover 7 Nm 0 7 m kg 5 1 ft lb ...

Page 167: ...S section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Clamp air filter joint 1 Only loosening 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 Only loosening 7 Adjuster 1 Only loosening 8 Lower spring guide 1 9 Upper spring guide 1 10 Spring rear shock absorber ...

Page 168: ...ck ab sorber be sure to extract the nitrogen gas from valve 1 Wear eye protec tion to prevent eye damage from es caping gas and or metal chips To dispose of a damaged or worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure REMOVING THE BEARING 1 Remove Stopper ring upper bearing 1 Press in the bearing while pressing its outer race and remove the stopper ring...

Page 169: ... the molybdenum disulfide grease on the bearing and dust seal lips Install the dust seals with their lips facing outward 3 Install Rear shock absorber 4 Install Bolt rear shock absorber frame 1 Washer 2 Nut rear shock absorber frame 3 Apply the molybdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 Apply the molybdenum disulfide g...

Page 170: ...ervicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowledge and skill concerning servicing are request ed not to undertake inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ...

Page 171: ...tion sensor 3 Neutral switch 4 CDI magneto 5 Ignition coil 6 Spark plug 7 CDI unit COLOR CODE B Black Br Brown G Green L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B L Black Blue B W Black White B Y Black Yellow G B Green Black L W Blue White R W Red White B W B W B L B Y Sb Sb G B L Y L Y P B B B B G O W R P G W R P B Br W W B Y G Br G R R O B Sb Sb Y Y W Y W G G B P P Br Br R R O L ...

Page 172: ...e following special tools in this inspection Spark gap test Spark Clean or replace spark plug No spark Check entire ignition system for connection couplers leads and ignition coil No good Repair or replace OK Check engine stop switch No good Replace OK Check ignition coil primary coil and secondary coil No good Replace OK Check CDI magneto pickup coil and charging coil No good Replace OK Check neu...

Page 173: ...emove the ignition coil cap 2 Inspect Primary coil resistance Out of specification Replace 3 Inspect Secondary coil resistance Out of specification Replace 4 Inspect Sealed portion of ignition coil a Spark plug terminal pin b Threaded portion of spark plug c Wear Replace CHECKING THE CDI MAGNETO 1 Inspect Pickup coil resistance Out of specification Replace 2 Inspect Charging coil 1 resistance Out ...

Page 174: ... engaged Re place Set the tester selection position to Ω 1 CHECKING THE CDI UNIT Check all electrical components If no fault is found replace the CDI unit Then check the electrical compo nents again Tester lead Pink lead 1 Tester lead Black lead 2 Charging coil 2 resis tance Tester se lector posi tion 44 66 Ω at 20 C 68 F Ω 10 Tester lead Sky blue lead 1 Tester lead Ground 2 Result Conductive whil...

Page 175: ... IGNITION SYSTEM section Use the following special tools in this inspection Check entire ignition system for connection No good Repair or replace OK Check throttle position sensor Throttle position sensor coil No good Replace OK Check CDI magneto Charging coil No good Replace OK Check CDI unit Throttle position sensor input voltage No good Replace Pocket tester YU 3112 C 90890 03112 ...

Page 176: ...sition sensor 1 Screw throttle position sensor 2 Align the slot a in the throttle posi tion sensor with the projection b on the carburetor Temporarily tighten the screw throttle position sensor 5 Install Carburetor Throttle position sensor coupler 6 Adjust Engine idling speed Refer to ADJUSTING THE EN GINE IDLING SPEED section in the CHAPTER 3 7 Insert the thin electric conductors 2 lead into the ...

Page 177: ...1 Tighten the screw throttle position sensor using the T25 bit 14 Install the carburetor CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor coupler 2 Start the engine 3 Inspect Throttle position sensor input volt age Out of specification Replace the CDI unit Throttle po sition sen sor output voltage Tester se lector posi tion 0 58 0 78 V DCV Tester lead B...

Page 178: ...cessarily Otherwise too much fuel may be discharged starting may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS The air density i e concentration of oxygen in the air determines the rich ness or leanness of the air fuel mix ture Higher temperature...

Page 179: ... up speed quickly Step down the jet needle clip by one groove and move up the nee dle to enrich the mixture Effects of changing the jet needle groove position reference A Idle B Fully open 1 No 5 groove 2 No 3 groove 3 No 4 groove ADJUSTING THE JET NEEDLE The jet needle is adjusted by chang ing it The jet needle setting parts having the same taper angle are available in different straight portion ...

Page 180: ...dard to lean out the mixture Example 70 80 CARBURETOR SETTING PARTS Standard leak jet 70 Main jet Size Part number Rich 188 4MX 14943 95 185 4MX 14943 44 182 4MX 14943 94 180 4MX 14943 43 STD 178 4MX 14943 93 175 4MX 14943 42 172 4MX 14943 92 170 4MX 14943 41 Lean 168 4MX 14943 91 Pilot jet Size Part number Rich 48 4MX 14948 06 STD 45 4MX 14948 05 STD 42 4MX 14948 04 40 4MX 14948 03 Lean 38 4MX 14...

Page 181: ...eaner NFPN 5 NFPP 5 NFPQ 5 NFPR 5 NFPS 5 NFPT 5 NFPU 5 Lean 1 leaner NFLN 5 NFLP 5 NFLQ 5 NHKR 3 NFLS 5 NFLT 5 NFLU 5 Except for USA and CDN Diameter of straight portion Rich Lean N P Q R S T U Rich 1 richer NFLN 6 NFLP 6 NFLQ 6 NFLR 6 NFLS 6 NFLT 6 NFLU 6 0 5 richer NFPN 5 NFPP 5 NFPQ 5 NFPR 5 NFPS 5 NFPT 5 NFPU 5 STD NFLN 5 NFLP 5 NFLQ 5 NFLR 5 NFLS 5 NFLT 5 NFLU 5 0 5 leaner NFPN 4 NFPP 4 NFPQ ...

Page 182: ...m the top Check that the accelerator pump operates smoothly except for rich mixture symp tom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower jet needle clip position 1 groove down 1 4 1 2 throttle Slow speed pick up Poor acceleration Raise jet needle clip position 1 groove up Closed to 1 4 throttle Hard breathing Speed down Use jet needle...

Page 183: ...e Under a stony or hard road condi tion the tire pressure should be higher to prevent a flat tire FRONT FORK SETTING The front fork setting should be made depending on the rider s feeling of an actual run and the circuit conditions The front fork setting includes the fol lowing three factors 1 Setting of air spring characteris tics Change the fork oil amount 2 Setting of spring preload Change the ...

Page 184: ...pension setting includes the following two factors 1 Setting of spring preload Change the set length of the spring Change the spring 2 Setting of damping force Change the rebound damping Change the compression damp ing CHOOSING SET LENGTH 1 Place a stand or block under the engine to put the rear wheel above the floor and measure the length a between the rear wheel axle center and the rear fender h...

Page 185: ...he ti tanium spring The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compression The I D mark a is marked at the end of the spring Spring specification varies accord ing to the color and quantity of I D marks In case of using a titanium spring prepare 2cps of the Yamaha genu ine parts Spring sheet 2 1C3 22565 00 and ...

Page 186: ...NG THE REAR SHOCK ABSORBER SPRING PRELOAD in the CHAPTER 3 Preload adjusting extent is the same for the titanium and steel springs Maximum Minimum Position in which the spring is turned in 13 mm 0 51 in from its free length Position in which the spring is turned in 1 5 mm 0 06 in from its free length ...

Page 187: ...ntire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to in crease damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Replace with stiff spring Stiff toward stroke end Oil amount Decrease oil amount by about 5 cm3 0 2 Imp oz 0 2 US oz Soft toward stroke end bottoming out Oil amount Increase oil amount by about 5 cm3 0 2 Imp o...

Page 188: ...eavy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression damping Turn adjuster clockwise about 1 clicks to in crease damping High compression damping Turn adjuster clockwise about 1 6 turn to in crease dampin...

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Page 190: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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